Replaceable Inserts Save Sawhorses

In one regard, these sawhorses are like any others — they get chewed
up with use. What’s different about them is they have a replaceable
insert made from 2x stock. Once this insert gets riddled with saw kerfs,
you simply replace it with a new one (Photo, right).

These sawhorses aren’t just one-trick ponies, either. In order to
save floor space, they stack together when it’s time to
“stable” the horses (Inset Photo).

To form an opening for the insert, the top of each sawhorse consists of two
rails made of ¾″-thick stock with a 2x spacer sandwiched
between. The rails are notched to make a socket for the legs to fit into.
After cutting these notches, glue and clamp the rails and spacer
together.

As for the insert, just cut it to size from 2x stock. It’s held in
place by a bolt that passes through a hole drilled in the rails and
insert.

The sawhorses are supported by splayed 2x4 legs that nest in the sockets in
the rails. To make them sit flat, you’ll need to cut a long bevel at
the top end of each leg (End View). An easy way to do this is
to use a hand saw (or band saw) and then sand the surface smooth.

Before attaching the legs, there’s one more thing to do. That’s
to cut a bevel on both ends of each leg so the sawhorses will sit flat on
the floor. After making the bevel cuts with a circular saw or miter saw,
glue and screw the legs in place.

To prevent the sawhorses from racking, I attached a ½″ plywood
gusset to each end. Notch the bottom edge of this gusset to allow the
sawhorses to stack together. Then glue and screw the gussets to the legs.